Synthetic aggregate and method of producing the same

ABSTRACT

A synthetic aggregate having a multiplicity of uses such as for mixing with a cementing material to form concrete, mortar or plaster is disclosed. The aggregate includes crushed fragments of a size which are capable of passing through mesh screen having sieve openings ranging from between about 19 mm and 75 microns. The aggregate fragments are made by curing and then crushing a compressed product. The compressed product is made by compressing an aqueous cementitious mixture comprising cement and at least one member selected from the group consisting of bottom ash and non-cementitious fly ash. The compressed product is cured so that it has a compressive strength of at least 600 psi.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application is a nonprovisional application claiming thebenefit under 35 USC 119(e) of U.S. provisional application Ser. No.60/222,565, filed on Aug. 3, 2000 and a continuation in part of priorapplication Ser. No. 09/020,156, filed Feb. 7, 1998 which is adivisional of prior application Ser. No. 08/701,117, filed Aug. 21,1996, now U.S. Pat. No 5,725,652, which is a continuation of priorapplication Ser. No. 08/537,466, filed Oct. 2, 1995, now U.S. Pat. No.5,622,556, which is a continuation in part of prior application Ser. No.08/358,858, filed Dec. 19, 1994, now U.S. Pat. No. 5,580,378.

FIELD OF THE INVENTION

[0002] The present invention provides novel compositions, methods oftheir use and methods of their manufacture, such compositions generallyuseful as agents in the construction and building trades. Morespecifically, the compounds of the present invention can be used inconstruction and building applications that benefit from a relativelylightweight, extendable, moldable, pourable cementitious material thathas high strength, good insulation properties and vermin resistanceproperties. At the present time, there is a need in the area ofconstruction and building for such agents.

BACKGROUND OF THE INVENTION

[0003] In the field of preparation and use of lightweight cementitiousmaterials, such as so-called lightweight aggregates the materials thathave been available to the trades up until now have generally requiredthe addition of various constituents to achieve a strong but lightweightconcrete mass that has a high homogeneity of constituents and which isuniformly bonded throughout the mass. Of the methods known to theinventor, there have been several patents issued relating to theinclusion of expanded polystyrene beads of an average bead size of about20 mm diameter (about 20,000 microns) that are expanded by variousheating methods either before the beads are introduced into the concretemixture, or expanded after they have been added to the concrete mixture.It is an object of this invention to provide for a pourable, lightweightcementitious mixture that does not rely on expanded polystyrene forweight saving properties and strength. It is another object of thepresent invention to provide for a pourable, lightweight cementitiousmixture that can be used in the construction of molded roofing tiles. Itis yet another object of the present invention to provide for apourable, lightweight cementitious mixture that can be used in theconstruction of laminated building foundations, that is, the type offoundations in which a cement pour product is poured in between formwalls that become part of the structural assembly upon curing of thecement. It is yet another object of the present invention to provide fora pourable, lightweight cementitious mixture that resists insectinfestation and deterioration. Yet another object of the presentinvention is to provide for an extendable cementitious mixture that canbe extruded through various extrusion dies and can be cured withoutfurther shape manipulation or formation. Still another object of theinvention is to provide for a cementitious mixture that can be moldedunder high pressure and readily ejected from the mold with a minimum ofgreen time to enable rapid re-cycling of the mold. Still one more objectof the invention is provide a synthetic aggregate by curing and crushinga compressed product of an aqueous cementitious mixture.

SUMMARY OF THE INVENTION

[0004] The last of the foregoing objects of the present invention, i.e.the production of a synthetic or man-made aggregate, is achieved bycuring and then crushing a compressed product made from an aqueouscementitious mixture comprising cement and at least one member selectedfrom the group consisting of bottom ash and non-cementitious fly ash.Other additives such as polystyrene for reducing the weight of thecompressed product but not its strength may also be added to themixture. Prior to crushing, it is also important to cure the compressedproduct so that it has a compressive strength of at least 600 psi. Oncecured, the compressed product is crushed into fragments of a size whichare capable of passing through mesh screen having sieve openings rangingfrom between about 19 mm and 75 microns. The crushed fragments nowreferred to herein as a synthetic or man-made aggregate is suitable fora multiplicity of uses such as for mixing with a cementing material toform concrete, mortar or plaster. Other uses include use as a filler andas a filtration media.

[0005] The invention comprises lightweight load bearing cementitiouscompositions that yield building materials having a density of 35 to 80lb/ft³, comprising from 40 to 99% by volume of aqueous cementitiousmixture and from 0 to 60% by volume of micronized polystyrene foamparticles, the foam particles having a minimum density of 1.0 lb/ft³,and the water content of the aqueous cementitious product being presentin a range of from 0.005 to 20% by volume. A more preferred range ofwater content is from 0.005% to 5% by volume, more preferably from0.005% to 2% by volume. Preferred ranges of cementitious mixtures andmicronized polystyrene foam particles are from 40 to 75% by volumecementitious mixtures and 25 to 60% by volume foam. More preferredranges of cementitious mixtures and micronized polystyrene foamparticles are from 50 to 60% by volume cementitious mixtures and 40 to50% by volume foam.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0006] The term “aqueous cementitious mixture” refers to any of a numberof compositions comprising water, a cement material, and one or morefillers or adjuvants that form a slurry that hardens upon curing. Cementmaterials include hydraulic cements, lime, and the like. Adjuvants andfillers include bottom ash, fly ash, aggregate, air entrainment agents,crushed glass, recycled plastic, colorant agents and so forth. Thecompositions of the invention include a class of low water weight cementmixtures that have only from about 0.005 to 5% v/v of water added to thefinal mix. Such low water compositions have surprisingly been found toproduce plastic cement mixtures that are readily processed through anextrusion die into a shape that needs no additional manipulation ormolding after having been cut off subsequent to exiting the extrusiondie. Also, the low water content compositions are well suited to beingmolded under high pressure, (e.g. in the range of five hundred to fivethousand lb/in²). The advantage of such high pressure molding operationsis that after removing the pressure, the molded article can be ejectedfrom the mold very quickly, usually after three to twenty seconds or so,thereby allowing the mold to be available for another cycle of moldinganother article. Ordinarily, when a plastic composition is being shapedin a mold, there is some period of time that the composition must remainin the mold until it has sufficiently hardened to at least remove itfrom the mold, a period known in the trade as ‘green time’. The longerthe green time of a given composition being used to mold articles, thefewer times the mold itself can be cycled during a work day. Theextrusion and high pressure molding techniques and apparatus used infabricating products out of the compositions of the invention are wellknown to those of ordinary skill in the art, and do not form a separatepart of the invention as claimed herein, except to the limited extentthey are a step in the process of making aggregate and articles out ofthe compositions of the invention. The compression stage of working withthe compositions of the invention causes the material to be compresseddown to approximately one third of its original volume. It has beenfound that articles molded out of these compositions lose the brittlequality of most molded cement or concrete compositions. For example, aroof tile pressure molded or extruded from these compositions doesn'tshatter if dropped on the floor from a height of about three to fourfeet.

[0007] The term “cement” as defined herein refers to inorganic materialscombined with water to form a hydrated bonded matrix. Hydraulic cementundergoes a hydration reaction in the presence of a sufficient quantityof water that produces the hardened product. The following are sometypical hydration reactions:

Ca₃Al₃O₆+6H₂O, Ca₃Al₂(OH)₁₂;

Ca₂SiO₄ +xH₂O—Ca₂Si)₄ —xH₂O;

Ca₃SiO₅+(x+1)H₂O E Ca₂SiO₄ —xH₂O+Ca(OH)₂

[0008] The most preferred hydraulic cement for use in the invention isportland cement. Various embodiments of the invention call for theaddition of lime (calcium oxide) which is itself also a hydrauliccement. Micronized polymeric particles comprise the weight savingcomponent of the present invention, and can be polystyrene, polyester,polyethylene, polypropylene, acrylic, polyisocyanurate, polyacrylamide,polyacrylimide, mixed imide-amides arylamides, arylimides and the like.The most preferred material is polystyrene. Micronized polystyrene foamparticulates are the result of a process of shredding virgin, and/orrecycled polystyrene foam, and give the final product its lightweightcharacteristics. The most preferred form of micronized polystyrene foamparticulates is made up of virgin polystyrene foam of approximately 1 to5 lb/ft.sup.3 density that has been treated with a borate. The borateacts as a potent insect repellant, tending to keep vermin insects awayfrom the rest of the structure of the building that incorporates suchborate-containing cement compositions. This is to be distinguished fromthe use cementitious compositions as a means of disposing of wasteinsecticides, including borate. Alternatively, a borate such asTIM-BOR.RTM. brand of borate available from U.S. Borax Co. can be addedin powder form to the cementitious mixture.

[0009] Such foam block is then shredded to provide the micronizedparticles having irregular surfaces. A particularly well suited methodof shredding is by running an electrified fine gauge wire through solidblocks of this foam, according to methods well known to those ofordinary skill in cutting and fabricating such polystyrene foam blocks.Alternatively, a wire brush can be used to brush against and abrade asolid foam block, thereby producing the desired small particulates offoam. This type of product is also generally available as a wasteby-product (“fines”) at facilities that cut virgin polystyrene foamblock. This process produces micronized foam particulates that can becharacterized by sieve analysis in general conformance with ASTM C 136,entitled “Sieve Analysis of Fine and Coarse Aggregates”. Such method ofanalysis is suitable for particles of from 50 to 5,000 microns in size.A more preferred range of foam particle size is from 50-2000 microns,more preferably from 600-1200 microns. A typical sample yielded thefollowing sieve analysis: Sieve Size Sieve Opening (in microns)Polystyrene % Passing No. 4 4760 100 No. 8 2380 99 No. 10 2000 99 No. 161260 80 No. 30 590 34 No. 50 297 8 No. 100 149 2 No. 200 74 1

[0010] From this analysis, it can be seen that the micronizedpolystyrene foam particulates preferred in the invention can becharacterized as a coarse to moderately coarse powder, as those termsare used in the science of rheology, having a median particle size ofapproximately 800 microns. Micronized foam of this type is availablefrom the R-Control Co. of Denver, Colo., and other major cities or fromPoudre Plastics of Fort Collins, Colo.

[0011] Fly ash of the cementitious type can be used as a partialreplacement for portland cement in concrete construction, and it isgenerally accepted that the proportion of portland cement replaced bythe usual fly ash should not exceed about 20% to avoid significantreduction in the compressive strength or the resultant concrete. Fly ashcomponents of the cementitious mixtures of the invention can be eitherC-type (“C-class”) or F-type (“F-class”) fly ash. Fly ash is the veryfinely divided ash produced by the combustion of anthracite andbituminous coal in large industrial coal-fired boilers, especially forthe steam generation of electricity, that is suspended in the flue gasesfrom such boilers and is separated therefrom by means such aselectrostatic precipitation. This fly ash is an extremely finely dividedmaterial generally in the form of spherical bead-like particles, with atleast 70% by weight passing a 200 mesh sieve and has a generally glassystate, resulting from fusion or sintering during combustion. Asrecognized in the American Society of Testing Materials (ASTM)specification designation C618-85 entitled “Fly Ash and Raw or CalcinedNatural Pozzolan for Use as a Mineral Admixture in Portland CementConcrete”, cementitious fly ash is subdivided into two distinctclassifications; namely, Class F and Class C. The definitions of thesetwo classes are as follows: “Class F-Fly ash normally produced fromburning antharacite or bituminous coal that meets the applicablerequirements for this class as given herein. This class fly ash haspozzolanic properties. Class C-Fly ash normally produced from lignite orsubbituminous coal that meets the applicable requirements for this classas given herein. This class of fly ash, in addition to having pozzolanicproperties, also has some cementitious properties. Some Class C flyashesmay contain lime contents higher than 10%.” The reference to “pozzalanicproperties” refers to the capability of certain mixtures, which are notin themselves cementitious, of undergoing a cementitious reaction whenmixed with lime (calcium oxide) in the presence of water. Class FFly-ashes can have from 4 to 9% calcium oxide contents, while Class CFly-ashes can have from 30 to 60% calcium oxide contents. For thisreason, Class C fly ash possesses direct cementitious properties as wellas pozzolanic properties. Fly ash is readily available from localbuilding products outlets. Fly ash that has been de-limed, which iscalled for in several embodiments of the cementitious compositions ofthe present invention, is also readily commercially available from avariety of local sources.

[0012] Bottom ash which is employed as a constituent in forming theaggregate of the present invention is also a byproduct produced by thecombustion of anthracite and/or bituminous coal. Bottom ash is actuallya residue of the combustion process which collects in the bottom of theboiler or generator as the coal is burned. Bottom ash has a similarchemical makeup to fly ash but a much coarser gradation. It typicallycontains SiO₂, Al₂O₃, Fe₂O₃. CaO, MgO, Na₂O, K₂O, TiO₂, MnO₂, P₂O₅, SrO,BaO and SO₃. However, its composition may vary from plant to plantdepending of the actual type of coal burned, the humidity and otherfactors as well. Bottom ash has little to no cementitious properties.Further information regarding bottom ash and its uses are disclosed inarticles entitled “Coal Bottom Ash/Boiler Slag” (author unknown) and“The Use of Recycled Materials in Highway Construction” by Robin L.Schroeder, both of which are published on the Turner-Fairbank HighwayResearch Center's web site at www.tfhrc.gov.

[0013] There is also a type of fly ash which has little or nocementitious properties which may also be used in producing theaggregate of the present invention. Non-cementitious fly ash istypically separated out from the cementitious fly ash at the plant as iswell known to those skilled in the art. The composition of suchnon-cementitious fly ash will also vary depending of the actual type ofcoal burned, the humidity and other factors known to those in the art.

[0014] The presence of an air entraining agent helps to create air cellsor voids in a batch of concrete, which can help to maintain goodworkability of fresh concrete and also improve the durability tofreezing and thawing of hardened concrete. Air entrainment agentsinclude anionic surfactants such as polyoxyethylene alkyl ether sulfatesor polyoxyethylene alkly phenyl ether sulfates or salts thereof,polyoxyethylene alkyl ether phosphates or polyoxyethylene alklyl phenylether phosphates or salts thereof, alkylbenzenesulfonic acids or saltsthereof, alpha-olefinic-sulfonic acids or salts thereof, fatty acids orsalts thereof, polyoxyethylene polyalcohol fatty acid esters,polyethylene glycol fatty acid esters, polyoxyethylene pentaerythryritolfatty acid esters and polyoxyethylene sorbitan fatty acid esters and thefatty acids or salts thereof.

[0015] Sand is frequently used to expand the volume of cementitiousmixtures. Sand used in the cementitious mixtures of the presentinvention include play sand whether from beach or river sources, andsilica sand. Clay is a suitable alternative for sand in the mixtures ofthe invention. An especially preferred volume expansion material isexpanded shale, clay and slate mix (ESCS). This material is a ceramiclightweight aggregate prepared by expanding select minerals in a ritarykiln at 1000 degrees celsius or more. This process results in a lightweight, inert material comprised of a mix of oxides including SiO₂,Al₂O₃, Fe₂O₃, CaO, MgO, K₂O, N₂O, SO₃, P₂O₅, TiO₂, Mn₂O₃, and CO₂. Thismaterial is available through the Expanded Shale, Clay and SlateInstitute, Salt Lake City, Utah, which makes a list available ofdistributors of this material throughout the United States. The use ofESCS can completely replace sand in the cementitious mixtures of theinvention, and produce an especially light final product in concert withthe foam particles described above.

[0016] As a means of reinforcing the product, reinforcement fibers canbe added to the cementitious mixtures of the invention. Such fibers actas reinforcing components, having a large aspect ratio, that is, theirlength/diameter ratio is high, so that a load is transferred acrosspotential points of fracture. Typical preferred materials are fiberglassstrands of approximately one to one and three fourths inches in length,although any material can be used that has a higher Young's modulus thanthe matrix of the cementitious material. Another preferred fiber arecommercially available from the Fibermesh company of Chatanooga, Tenn.,and are comprised of polypropylene fiber. In those embodiments of theinvention that include the use of reinforcing fibers, the final moldedproduct often displays a hair-like external appearance. Such extraneousfiber hairs can be burned off with a suitable torch.

[0017] Densities of products using the compositions of the presentinvention can vary from 60 to 115 lb/ft³, preferably 35-90 lb/ft³, withmany products being about 50 lb/ft³.

[0018] The compositions of the invention are well suited to thefabrication of molded construction materials, especially roofing tilesand foundation walls. The compositions are easier to pour than regularweight mixtures and exhibit greater strength. The compositions can bereadily cast into molds according to methods well known to those ofskill in the art for roofing tiles in virtually any three dimensionalconfiguration desired, including configurations having certain topicaltextures such as having the appearance of wooden shakes, slate shingles,or smooth faced ceramic tiles. A typical shingle can have approximatedimensions of ten inches in width by seventeen inches in length by oneand three-quarters inches in thickness. In the molding of roofingmaterials, the addition of an air entrainment agent makes the finalproduct more water resistant.

[0019] When foundation walls are poured using the lightweightcementitious compositions of the invention, the walls can be taken abovegrade due to the lighter weight. Ordinarily, the lower part of thefoundation wall has a tendency to blow outwards under the sheer weightof the concrete mixture, but the lighter weight of the compositions ofthe invention tend to lessen the chances of this happening. Foundationwalls prepared using these compositions can readily take conventionalfasteners used in conventional foundation wall construction. Aparticularly preferred type of foundation wall construction calls forthe use of foam plastic walls to form a sandwich containing the pouredlightweight concrete. After hardening, the foam walls are left intact toadd significantly to the insulation properties of the foundation walls.Such walls can be made of extruded polystyrenes or the like, andfrequently are available to contractors in preformed wall and cornerunits that snap or clip together, according to methods well known tothose in the construction trades.

[0020] Additionally, the cementitious compositions of the invention canbe used as a stucco or as a plaster, being applied by any means wellknown to those of ordinary skill in those trades; as a wall board, ofthe sandwich type of construction wherein the hardened material issandwiched by suitably strong paper or other construction material; aspavers for sidewalks, roofs, driveways and the like; as a pour materialfor sidewalks, driveways and the like; as a monolithic pour material forfloors of buildings; as molded chimney stacks or smoke stacks; asbricks; as fire or refractory bricks for fireplaces, furnaces, cruciblesand the like; as roof pavers; as monolithic pour material for radiantheat floor systems; as blocks for landscape retaining walls; asprestressed concrete wall systems; as tilt-up wall systems, i.e. where awall component as poured on site and then tilted up when hardened; andas mason's mortar.

[0021] A stucco preparation means a finish for walls, made from sand,lime and cement mixed with water, that, as a covering for walls, isapplied wet and dries hard and durable to form a rough finish forexterior walls.

[0022] A paver is a brick molded so as to be easily laid down upon asubstantially horizontal roadbed or walkway surface to form an uppersurface that can support foot or vehicular traffic. Pavers find commonuse in construction of walkways and driveways. A roof paver is aparticularly thin type of paver that can be used as a roofing material,assuming that the builder has built a substantial enough framework ofroof rafters. Roof pavers are also known as cement shingles, and aresometimes molded and colored so as to imitate the appearance of slateshingles wood shingles, or ceramic shingles. They are sometimesreinforced with fibers.

[0023] A plaster preparation is a mixture of cementitious materials andwater that forms a plastic mass that is used as a finish for walls, likestucco is applied wet and dries hard and durable to form a rough or finefinish for interior walls.

[0024] A pour product for the pouring of building floors refers to acement and water mixture that can be poured into molds defining thefloor of a building room or section, so that when the mass dries andhardens, a usable, load-beating floor is formed. A pour product for thepouring of radiant heat floors is similar except that the builder haslaid down hollow tubing in the mold area defining the floor to bepoured. The tubing is intended to conduct heated liquids, typicallywater. On top of the tubing, wet pour product is poured. The masssubsequently dries and hardens, producing a flat smooth floor surfacethat has the tubing embedded within it. Hot water is then pumped throughthe hollow tubing, which heats the entire hardened floor, which in turnradiates heat into the room.

[0025] A prestressed concrete wall system product is a molded,pre-formed panel or structural member made up of a concrete mixture inwhich embedded high-tensile steel is stretched, and then the stress istransferred to the concrete by bonding to the steel or by anchorages tothe steel. Panels or structural members can be formed or molded intogirders, load-bearing panels, floor sections, wall sections, and thelike. In this application, applicants are claiming as a product byprocess, such prestressed molded products using the lightweightcomposition, as members to construct walls.

[0026] A tilt-up type of wall system product refers to a pre-molded orprecast concrete structural member that is poured while the mold islying down, i.e. the intended vertical wall surface is laid downhorizontally. Upon drying and curing, the horizontally-oriented wall orpanel member is then tilted up until it is vertically oriented and movedinto place as a constituent member of a wall system of a building. Suchtilt-up wall components can form foundations below grade, or wallsystems above grade.

[0027] Preferred aqueous mixtures from which the aggregate product ofthe invention are made include any or all of those specifically setforth in the following examples. We have found that the most preferredaqueous mixtures use 4 parts cement, 2 parts water, 10 parts bottom ashand polystyrene foam in parts ranging from 0 to 40 parts. However, foamin 15 parts is the most preferred since it significantly reduces theweight of product produced and still provides high compressive strengthson the order of about 3000 psi. While these are the preferred mixtures,these are not to be construed as forming the only genus that isconsidered as the invention, and any combination of themixtures'components may itself form a genus. The following examplesfurther illustrate details for the preparation of the mixtures of thepresent invention. Those skilled in the art will readily understand thatknown variations of the conditions and processes of the followingpreparative procedures can be used to prepare these compositions.

[0028] In each of the following examples, the mixes were prepared at atemperature of approximately 40 degrees Fahrenheit or above.Measurements, unless noted otherwise, are given as parts of volume tovolume measures, abbreviated as v/v. Parts for these type of mixturesare most conveniently measured as cylinders of approximately 6 inches inlength by 4 inches in diameter. Strength tests were conducted accordingto the ASTM C 39 protocol, the text of which is incorporated herein byreference.

EXAMPLE 1

[0029] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0030] 1 parts v/v of F-type fly ash that has been de-limed.

[0031] 4 parts v/v Portland cement.

[0032] 10 parts v/v bottom ash

[0033] 15 parts v/v micronized polystyrene foam particles.

[0034] 2.5 parts v/v water

[0035] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 4,000 psi and held for 20 seconds. The resultingproduct had a compressive strength of 2,200 psi.

EXAMPLE 2

[0036] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0037] 2 parts v/v of C-type fly ash that has been de-limed.

[0038] 5 parts v/v Portland cement.

[0039] 10 parts v/v bottom ash.

[0040] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 4,000 psi and held for 20 seconds. The resultingproduct had a compressive strength of 2,950 psi.

EXAMPLE 3

[0041] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0042] 2 parts v/v of C-type fly ash that has been de-limed.

[0043] 5 parts v/v Portland cement.

[0044] 10 parts v/v bottom ash.

[0045] 3 parts v/v micronized polystyrene foam particles.

[0046] 0.5 parts v/v water.

[0047] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 4,000 psi and held for 20 seconds. The resultingproduct had a compressive strength of 2,650 psi.

EXAMPLE 4

[0048] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0049] 2 parts v/v of F-type fly ash.

[0050] 5 parts v/v Portland cement.

[0051] 10 parts v/v bottom ash.

[0052] 3 parts v/v micronized polystyrene foam particles.

[0053] 1.5 parts v/v water.

[0054] 0.25 parts v/v water proofer (latex)

[0055] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 400 psi and held for 20 seconds under a sonicvibration table. The resulting product had a compressive strength of6,220 psi.

EXAMPLE 5

[0056] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0057] 2 parts v/v of F-type fly ash.

[0058] 5 parts v/v Portland cement.

[0059] 10 parts v/v bottom ash.

[0060] 5 parts v/v micronized polystyrene foam particles.

[0061] 1.5 parts v/v water

[0062] 0.25 parts v/v water proofer (latex)

[0063] The above ingredients were dry mixed for five minutes, and asufficient quantity of water is added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 400 psi and held for 20 seconds under a sonicvibration table. The resulting product had a compressive strength of6,022 psi.

EXAMPLE 6

[0064] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0065] 2 parts v/v of F-type fly ash.

[0066] 4.5 parts v/v Portland cement.

[0067] 10 parts v/v bottom ash.

[0068] 5 parts v/v micronized polystyrene foam particles.

[0069] 1.5 parts v/v water

[0070] 0.25 parts v/v water proofer (latex)

[0071] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 400 psi and held for 20 seconds under a sonicvibration table. The resulting product had a compressive strength of3,000 psi.

EXAMPLE 7

[0072] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0073] 2 parts v/v of F-type fly ash.

[0074] 3.5 parts v/v Portland cement.

[0075] 10 parts v/v bottom ash.

[0076] 5 parts v/v micronized polystyrene foam particles.

[0077] 20 1.75 parts v/v water

[0078] 0.25 parts v/v water proofer (latex)

[0079] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 400 psi and held for 20 seconds under a sonicvibration table. The resulting product had a compressive strength of3,258 psi.

EXAMPLE 8

[0080] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0081] 1 parts v/v of F-type fly ash.

[0082] 4 parts v/v Portland cement.

[0083] 10 parts v/v bottom ash.

[0084] 15 parts v/v micronized polystyrene foam particles.

[0085] 1.75 parts v/v water

[0086] 0.25 parts v/v water proofer (latex)

[0087] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 4,000 psi and held for 20 seconds under a sonicvibration table. The resulting product had a compressive strength of3,258 psi.

EXAMPLE 9

[0088] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0089] 1 parts v/v of F-type fly ash.

[0090] 4 parts v/v Portland cement.

[0091] 10 parts v/v bottom ash.

[0092] 12 parts v/v micronized polystyrene foam particles.

[0093] 1.75 parts v/v water

[0094] 0.25 parts v/v water proofer (latex)

[0095] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 2,000 psi and held for 10 seconds. The resultingproduct had a compressive strength of 2,800 psi.

EXAMPLE 10

[0096] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0097] 1 parts v/v of F-type fly ash.

[0098] 4 parts v/v Portland cement.

[0099] 10 parts v/v bottom ash.

[0100] 15 parts v/v micronized polystyrene foam particles.

[0101] 5 1.75 parts v/v water

[0102] 0.25 parts v/v water proofer (latex)

[0103] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 4,000 psi and held for 20 seconds. The resultingproduct had a compressive strength of 3,290 psi.

EXAMPLE 11

[0104] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0105] 1 parts v/v of F-type fly ash.

[0106] 5 parts v/v Portland cement.

[0107] 10 parts v/v bottom ash.

[0108] 1.75 parts v/v water

[0109] 0.25 parts v/v water proofer (latex)

[0110] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 4,000 psi and held for 20 seconds. The resultingproduct had a compressive strength of 4,010 psi.

EXAMPLE 12

[0111] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0112] 2 parts v/v of F-type fly ash.

[0113] 3.5 parts v/v Portland cement.

[0114] 10 parts v/v bottom ash.

[0115] 5 parts v/v micronized polystyrene foam particles.

[0116] 1.75 parts v/v water

[0117] 0.25 parts v/v water proofer (latex)

[0118] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 4,000 psi and held for 20 seconds. The resultingproduct had a compressive strength of 3,258 psi.

EXAMPLE 13

[0119] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0120] 2 parts v/v of F-type fly ash.

[0121] 3.5 parts v/v Portland cement.

[0122] 10 parts v/v bottom ash.

[0123] 5 parts v/v micronized polystyrene foam particles.

[0124] 1.75 parts v/v water

[0125] 0.25 parts v/v water proofer (latex)

[0126] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 4,000 psi and held for 20 seconds. The resultingproduct had a compressive strength of 2,645 psi.

EXAMPLE 14

[0127] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0128] 2 parts v/v of F-type fly ash.

[0129] 4.5 parts v/v Portland cement.

[0130] 10 parts v/v bottom ash.

[0131] 5 parts v/v micronized polystyrene foam particles.

[0132] 5 1.75 parts v/v water

[0133] 0.25 parts v/v water proofer (latex)

[0134] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 2,000 psi and held for 5 seconds. The resultingproduct had a compressive strength of 4,115 psi.

EXAMPLE 15

[0135] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0136] 2 parts v/v of F-type fly ash.

[0137] 4.5 parts v/v Portland cement.

[0138] 10 parts v/v bottom ash.

[0139] 5 parts v/v micronized polystyrene foam particles.

[0140] 1.75 parts v/v water

[0141] 0.25 parts v/v water proofer (latex)

[0142] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 4,000 psi and held for 5 seconds. The resultingproduct had a compressive strength of 3,859 psi.

EXAMPLE 16

[0143] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0144] 2 parts v/v of F-type fly ash.

[0145] 3.5 parts v/v Portland cement.

[0146] 10 parts v/v bottom ash.

[0147] 10 parts v/v micronized polystyrene foam particles.

[0148] 1.75 parts v/v water

[0149] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 2,000 psi and held for 5 seconds. The resultingproduct had a compressive strength of 3,636 psi.

EXAMPLE 17

[0150] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0151] 2 parts v/v of F-type fly ash.

[0152] 3.5 parts v/v Portland cement.

[0153] 10 parts v/v bottom ash.

[0154] 10 parts v/v micronized polystyrene foam particles.

[0155] 1.75 parts v/v water

[0156] 0.25 parts v/v water proofer (latex)

[0157] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 4,000 psi and held for 20 seconds. The resultingproduct had a compressive strength of 3,680 psi.

EXAMPLE 18

[0158] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0159] 2 parts v/v of F-type fly ash.

[0160] 3.5 parts v/v Portland cement.

[0161] 10 parts v/v bottom ash.

[0162] 10 parts v/v micronized polystyrene foam particles.

[0163] 1.75 parts v/v water

[0164] 0.25 parts v/v water proofer (latex)

[0165] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 2,000 psi and held for 5 seconds. The resultingproduct had a compressive strength of 3,636 psi.

EXAMPLE 19

[0166] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0167] 2 parts v/v of F-type fly ash.

[0168] 3.5 parts v/v Portland cement.

[0169] 10 parts v/v bottom ash.

[0170] 10 parts v/v micronized polystyrene foam particles.

[0171] 1.75 parts v/v water

[0172] 0.25 parts v/v water proofer (latex)

[0173] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 4,000 psi and held for 10 seconds. The resultingproduct had a compressive strength of 3,880 psi.

EXAMPLE 20

[0174] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0175] 2 parts v/v of F-type fly ash.

[0176] 3.5 parts v/v Portland cement.

[0177] 10 parts v/v bottom ash.

[0178] 10 parts v/v micronized polystyrene foam particles.

[0179] 1.75 parts v/v water

[0180] 0.25 parts v/v water proofer (latex)

[0181] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 2,000 psi and held for 15 seconds. The resultingproduct had a compressive strength of 3,940 psi.

EXAMPLE 21

[0182] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0183] 2 parts v/v of F-type fly ash.

[0184] 3.5 parts v/v Portland cement.

[0185] 10 parts v/v bottom ash.

[0186] 10 parts v/v micronized polystyrene foam particles.

[0187] 1.75 parts v/v water

[0188] 0.25 parts v/v water proofer (latex)

[0189] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed in a hydraulicpress to a pressure of 4,000 psi and held for 20 seconds. The resultingproduct had a compressive strength of 3,900 psi.

EXAMPLE 22

[0190] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0191] 1 parts v/v of F-type fly ash.

[0192] 4 parts v/v Portland cement.

[0193] 10 parts v/v bottom ash.

[0194] 15 parts v/v micronized polystyrene foam particles.

[0195] 1.75 parts v/v water

[0196] 0.25 parts v/v water proofer (latex)

[0197] 0.25 parts v/v plasticizer

[0198] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed by molding itunder 300 psi in a block/paver press and then vibrated and heated for 8seconds. The resulting product had a compressive strength of 3,950 psi.

EXAMPLE 23

[0199] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0200] 1 parts v/v of F-type fly ash.

[0201] 4 parts v/v Portland cement.

[0202] 10 parts v/v bottom ash.

[0203] 15 parts v/v micronized polystyrene foam particles.

[0204] 2 parts v/v water

[0205] 0.25 parts v/v water proofer (latex)

[0206] 0.25 parts v/v plasticizer

[0207] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed by molding itunder 300 psi in a block/paver press and then vibrated and heated for 8seconds. The resulting product had a compressive strength of 2,950 psi.

EXAMPLE 24

[0208] A cementitious composition was prepared by mixing the followingcomponents under the following conditions:

[0209] 1 parts v/v of F-type fly ash.

[0210] 4 parts v/v Portland cement.

[0211] 10 parts v/v bottom ash.

[0212] 25 parts v/v micronized polystyrene foam particles.

[0213] 1.75 parts v/v water

[0214] 0.25 parts v/v water proofer (latex)

[0215] 0.25 parts v/v plasticizer

[0216] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed by molding itunder 300 psi in a block/paver press and then vibrated and heated for 8seconds. The resulting product had a compressive strength of 950 psi.

EXAMPLE 25

[0217] A cementitious composition is prepared by mixing the followingcomponents under the following conditions:

[0218] 1 parts v/v of F-type fly ash.

[0219] 4 parts v/v Portland cement.

[0220] 10 parts v/v bottom ash.

[0221] 40 parts v/v micronized polystyrene foam particles.

[0222] 2 parts v/v water

[0223] 0.25 parts v/v water proofer (latex)

[0224] 0.25 parts v/v plasticizer

[0225] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed by molding itunder 2,000 psi for 15 seconds. The resulting product had a compressivestrength of 600 psi.

EXAMPLE 26

[0226] A cementitious composition is prepared by mixing the followingcomponents under the following conditions:

[0227] 1 parts v/v of F-type fly ash.

[0228] 4 parts v/v Portland cement.

[0229] 3 parts v/v crushed glass having a particle size ranging from ⅛inch diameter to ¼ inch diameter.

[0230] 10 parts v/v bottom ash.

[0231] 10 parts v/v micronized polystyrene foam particles.

[0232] 2 parts v/v water

[0233] 0.25 parts v/v water proofer (latex)

[0234] 0.25 parts v/v plasticizer

[0235] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed by molding itunder 2,000 psi for 15 seconds. The resulting product had a compressivestrength of 4000 psi.

EXAMPLE 27

[0236] A cementitious composition is prepared by mixing the followingcomponents under the following conditions:

[0237] 1 parts v/v of F-type fly ash.

[0238] 4 parts v/v Portland cement.

[0239] 3 parts v/v crushed glass having a particle size ranging from ⅛inch diameter to ¼ inch diameter.

[0240] 10 parts v/v bottom ash.

[0241] 2 parts v/v water

[0242] 0.25 parts v/v water proofer (latex)

[0243] 0.25 parts v/v plasticizer

EXAMPLE 28

[0244] A cementitious composition is prepared by mixing the followingcomponents under the following conditions:

[0245] 1 parts v/v of F-type fly ash.

[0246] 4 parts v/v Portland cement.

[0247] 3 parts v/v crushed recycled plastic having a particle sizeranging from ⅛ inch diameter to ¼ inch diameter.

[0248] 10 parts v/v bottom ash.

[0249] 2 parts v/v water

[0250] 0.25 parts v/v water proofer (latex)

[0251] 0.25 parts v/v plasticizer

[0252] The above ingredients were dry mixed for five minutes, and asufficient quantity of water was added to bring the volume of waterpresent to 5% v/v. The aqueous mix was then compressed by molding itunder 2,000 psi for 15 seconds. The resulting product had a compressivestrength of 2500 psi.

[0253] While the invention has been described and illustrated withreference to certain preferred embodiments thereof, those skilled in theart will appreciate that various changes, modifications andsubstitutions can be made therein without departing from the spirit andscope of the invention. It is intended, therefore, that the invention belimited only by the scope of the claims which follow and that suchclaims be interpreted as broadly as is reasonable.

I claim:
 1. An aggregate having a multiplicity of uses such as formixing with a cementing material to form concrete, mortar or plaster,said aggregate comprising: crushed fragments having a particle size soas to pass through mesh screen having sieve openings ranging frombetween about 19 mm and 75 microns, said fragments being made by curingand crushing a compressed product which is made by compressing anaqueous cementitious mixture comprising cement and at least one memberselected from the group consisting of bottom ash and non-cementitiousfly ash and wherein said cured compressed product has a compressivestrength of at least 600 psi.
 2. An aggregate as claimed in claim 1 ,wherein said aqueous cementitious mixture comprises between about 5 to40% by volume cement, 15 to 75% by volume bottom ash or non-cementitiousfly ash and up to 30% by volume water.
 3. An aggregate as claimed inclaim 1 , wherein said aqueous cementitious mixture comprises betweenabout 15 to 25% by volume cement, 20 to 60% by volume bottom ash ornon-cementitious fly ash and up to 20% by volume water.
 4. An aggregateas claimed in claim 1 , wherein said aqueous cementitious mixturecomprises between about 5 to 40% by volume cement, 15 to 75% by volumebottom ash or non-cementitious fly ash, 1-60% by volume polymericmaterial and up to 30% by volume water.
 5. An aggregate as claimed inclaim 1 , wherein said aqueous cementitious mixture comprises betweenabout 15 to 25% by volume cement, 20 to 60% by volume bottom ash ornon-cementitious fly ash, 20-50% by volume polymeric material and up to20% by volume water.
 6. An aggregate as claimed in claim 1 , whereinsaid aqueous cementitious mixture further comprises a at least onemember selected from the group consisting of ASTM Class C or ASTM ClassF cementitious fly ash.
 7. An aggregate as claimed in claim 1 , whereinsaid aqueous cementitious mixture further comprises borate insectrepellant.
 8. An aggregate as claimed in claim 1 , wherein said aqueouscementitious mixture further comprises polymeric materials.
 9. Anaggregate as claimed in claim 1 , wherein said aqueous cementitiousmixture further comprises up to 60% by volume of polystyrene particles.10. An aggregate as claimed in claim 1 , wherein said aqueouscementitious mixture further comprises an air entrainment agent.
 11. Anaggregate as claimed in claim 1 , wherein said aqueous cementitiousmixture additionally comprises latex.
 12. An aggregate as claimed inclaim 1 , wherein said aqueous cementitious mixture additionallycomprises a plasticizer.
 13. An aggregate as claimed in claim 1 whereinsaid cured compressed product has a water content from 0.005% to 2% byvolume.
 14. An aggregate as claimed in claim 1 , wherein said cementcomprises a hydraulic cement.
 15. An aggregate as claimed in claim 1 ,wherein said cement comprises a portland cement.
 16. An aggregate asclaimed in claim 1 , wherein said cement comprises lime.
 17. Anaggregate as claimed in claim 1 , wherein said aqueous cementitiousmixture further comprises fiberglass reinforcing fibers.
 18. Anaggregate as claimed in claim 1 wherein said cured compressed producthas a density of from 35 to 115 lb/ft³.
 19. An aggregate as claimed inclaim 1 wherein said cured compressed product has a density of from 40to 100 lb/ft³.
 20. An aggregate as claimed in claim 1 wherein said curedcompressed product has a density of from 45 to 95 lb/ft³.
 21. Anaggregate as claimed in claim 1 , wherein said aqueous cementitiousmixture further comprises up to 50% by volume of crushed glass.
 22. Anaggregate as claimed in claim 1 , wherein said aqueous cementitiousmixture further comprises up to 30% by volume of crushed plastic.
 23. Amethod of preparing an aggregate having a multiplicity of uses such asfor mixing with a cementing material to form concrete, mortar orplaster, said method comprising the steps of: (a) forming a cementitiousmixture suitable for undergoing a hydration reaction in the presence ofwater, said mixture containing cement and at least one member selectedfrom the group consisting of bottom ash and non-cementitious fly ash;(b) compressing the cementitious mixture under pressure ranging from 200to 5,000 lb/in² to form a compressed product; (c) curing the compressedproduct so that the product has a compressive strength of at least 600lb/in²; and (d) crushing the cured product into fragments having aparticle size so as to pass through mesh screen having sieve openingsranging from between about 19 mm and 75 microns.
 24. The method asclaimed in claim 23 , wherein said compression step comprises extrudingthe product of step (a) through an extrusion means under pressure. 25.The method as claimed in claim 23 , wherein said compression stepcomprises molding the product of step (a) in a mold under pressure. 26.The method as claimed in claim 23 further comprising adding polymericmaterials to the cementitious mixture of step (a).
 27. The method asclaimed in claim 26 wherein the polymeric materials include polystyreneparticles.
 28. The method as claimed in claim 23 further comprisingadding a sufficient quantity of water to bring the volume of waterpresent in the mixture to between about 0.005% to 5%.